EP2886302A2 - Verfahren zur Herstellung von verstärkten Materialien und Material erhältlich aus diesem Verfahren - Google Patents

Verfahren zur Herstellung von verstärkten Materialien und Material erhältlich aus diesem Verfahren Download PDF

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Publication number
EP2886302A2
EP2886302A2 EP14196374.4A EP14196374A EP2886302A2 EP 2886302 A2 EP2886302 A2 EP 2886302A2 EP 14196374 A EP14196374 A EP 14196374A EP 2886302 A2 EP2886302 A2 EP 2886302A2
Authority
EP
European Patent Office
Prior art keywords
core material
pin
core
heated
reinforced
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP14196374.4A
Other languages
English (en)
French (fr)
Other versions
EP2886302B1 (de
EP2886302A3 (de
Inventor
Christian Weimer
Patricia Parlevliet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Airbus Defence and Space GmbH
Original Assignee
Airbus Defence and Space GmbH
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Filing date
Publication date
Application filed by Airbus Defence and Space GmbH filed Critical Airbus Defence and Space GmbH
Publication of EP2886302A2 publication Critical patent/EP2886302A2/de
Publication of EP2886302A3 publication Critical patent/EP2886302A3/de
Application granted granted Critical
Publication of EP2886302B1 publication Critical patent/EP2886302B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/725—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs
    • B29C66/7252—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs hollow-walled
    • B29C66/72525—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs hollow-walled comprising honeycomb cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/725—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs
    • B29C66/7254—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being hollow-walled or honeycombs honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/142—Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • B29C65/167—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding using laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/3608—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
    • B29C65/3612—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements comprising fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
    • B29C65/3676—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73771—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73773—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91941—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined
    • B29C66/91943—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined higher than said glass transition temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/60—Multitubular or multicompartmented articles, e.g. honeycomb
    • B29L2031/608—Honeycomb structures

Definitions

  • the invention relates to the design and the production of reinforcing elements penetrating in the thickness direction of the core composite for reinforcing core composite structures.
  • Core composite structures typically include a relatively thick core layer of low bulk density, e.g. honeycomb core structure formed of foam or vertically extending cells of hexagonal cross section, and optionally cover layers.
  • the transverse (eg compressive and tensile stiffness and strength) perpendicular to the plane of the core composite and the shear stiffness and strength in the plane of the core composite can be improved.
  • composites and in particular core composite structures find a wide range of applications in the field of aircraft construction.
  • Such composite materials for example core composite structures, are generally formed from an upper and a lower cover layer or cover layer, between which, to increase the rigidity, a layer of low density, for example of foam or may be located honeycomb-like, usually filled, core structure formed from vertically extending cells of hexagonal cross-section.
  • Foams are particularly useful in component manufacturing as well as advanced component properties due to their multi-functionality for use in core composites for large-sized structural components, e.g. in the field of aviation.
  • To reinforce the foam-based core composites usually sewing or prepreg pinning techniques are used, with which fibers or threads can be introduced into hard foam components. After a resin infiltration process, the fiber interspersed areas then contribute to the mechanical strengthening of the foam.
  • the fibers or threads introduced for reinforcement may be so-called rovings, which consist of fibers running in parallel. They may also be threads consisting of twisted or twisted fibers
  • DE 10 2005 024 408 A1 describes the reinforcement of foam materials by means of a knotting process, in which first the needle pierces the material to be reinforced (the foam material) and only then, in the region of the underside of the foam material, absorbs the textile semi-finished and pulls in the following backward movement through the pierced hole.
  • WO 2007/012353 describes a manufacturing method for reinforcing core materials for core composites wherein first a hole is pierced by means of a gripper in the core composite and the reinforcing material is pulled by this gripper into the core material.
  • the connection between reinforcing material and core material can still be improved.
  • the described embodiments equally relate to the manufacturing method, the tool, the sandwich structure and the aircraft.
  • the Kernvernbunde obtainable from the process of the invention have good stability.
  • the pin connects directly to the core material as both the pin and core material soften and bond in the process. It is believed that upon insertion of the pin material of the core material displaces, which partially fills the adjacent pores and thus leads to a larger contact area between the core material and pin which leads to the increased stability.
  • Suitable thermoplastics are, for example, polyetherimide, polyetheretherketones, polyamide, polyimide, polyethersulfone, polyurethane or polyvinyl chloride, or mixtures thereof.
  • Polyamide, polyetherimide, polyetheretherketones, or mixtures thereof are preferred, e.g. a blend of polyetherimide and polyetheretherketone in a weight ratio of 65:35 to 35:65.
  • polymeric constituent means the totality of all polymers contained in the particular material, eg, pin, core material.
  • the pin and core material contain the same type or types of thermoplastic (s).
  • thermoplastic material means that it is the same type of plastic but the material of the core and the pin have different physical properties, e.g. Molecular weight, can have.
  • the pencil contains, for example, a polyetherimide having a molecular weight of 50,000 g / mol and the core material a polyetherimide having a molecular weight of 80,000 g / mol.
  • the plastics are thus of the same type (polyetherimide) but have different molecular weights, so they are the same type of thermoplastic.
  • Pen and / or core material may also contain blends of thermoplastics.
  • the same types of thermoplastic are each used.
  • the mixing ratio within the core material and the pin may be different.
  • the stick contains, for example, a mixture of a polyetherimide having a molecular weight of 50,000 g / mol and a polyetheretherketone having a molecular weight of 70,000 g / mol in a mixing ratio of 50:50.
  • the core material contains, for example, a mixture of a polyetherimide having a molecular weight of 80,000 g / mol and a polyetheretherketone having a molecular weight of 1,200,000 g / mol in a mixing ratio of 60:40.
  • the plastics are thus of the same type (polyetherimide / polyetheretherketone) but have different molecular weights and weight ratios, so are the same types of thermoplastic.
  • the pin and core material contain the same thermoplastic or mixture of thermoplastics.
  • the same thermoplastic means that the same plastic material is used for the pin and core material.
  • the same mixture of thermoplastics means that the individual plastics contained in the mixture are the same as well as the mixing ratio.
  • the polymeric component of the pin and the core material each at least 90 wt .-% of the same thermoplastic material or the same mixture of thermoplastics.
  • the polymeric component of the core material is 100% by weight of the same thermoplastic or mixture of thermoplastics as the pin.
  • the pin is fiber reinforced.
  • the fiber-reinforced pin is a pultrudate.
  • the pin preferably consists of the same thermoplastic material or the same mixture of thermoplastic materials as the core material and, optionally, the fibers used for reinforcement.
  • thermoplastics may be amorphous or semi-crystalline polymers.
  • the temperature at which the pin and / or the core material is heated at the point of introduction is usually above the glass transition temperature T g of the thermoplastic material of the core material or of the pin, determined by means of differential scanning calorimetry according to DIN 65467.
  • the temperature is normally not higher than the melting point (T m ) + 50 ° C of the semicrystalline polymer of the Kermaterials or the pin, determined by means of differential scanning calorimetry according to DIN 65467th
  • the temperature is normally not higher than the glass transition temperature (T g ) + 50 ° C. of the amorphous polymer of the core material or of the pencil, determined by means of differential scanning calorimetry according to DIN 65467.
  • the material has more than one glass transition temperature, then the o.g. Area to set the lowest glass transition temperature.
  • the highest melting temperature should be used for the above-mentioned range.
  • the temperature of the core material and the pin is usually selected from the above ranges.
  • the cross-sectional area of the pin is usually not more than 35 mm 2
  • the pen may e.g. be round, oval or have corners.
  • the pin is also heated indirectly on contact with the heated core material.
  • the pin and optionally the core material is heated.
  • the pin may be pointed to facilitate insertion into the core material.
  • the core material is advantageously particle-reinforced.
  • These particles are preferably metallic particles.
  • metallic particles e.g. Induction heating can be used. But the heating by means of LEDs, laser and electron beams is facilitated.
  • a hole may optionally be drilled or punched in the core material.
  • Such a hole is usually smaller than the pin that is inserted.
  • “Smaller” in this case means that not only is the cross-sectional area of the hole smaller than the cross-sectional area of the pin, but that the cross-sectional area of the hole is completely within the cross-sectional area of the pin.
  • Such a hole reduces the amount of core material displaced by the pin during insertion, which in addition leads to a reduced weight of the core composite structure. This is particularly advantageous in the aerospace industry.
  • the risk is reduced that softened or molten core material is removed from the core which must be removed.
  • the heating of the pin or the core material can be done for example by LEDs, laser, electron beams or induction. Such methods are known to the person skilled in the art.
  • the volume of the core material which is heated is not more than four times the volume occupied by the pin within the core material, preferably not more than three times.
  • the pin may protrude beyond the core material or terminate with the core material.
  • the core material corresponds to the volume which the pin within the core material occupies the volume of the pin. Should the pin protrude on one or both sides, the volume occupied by the pin within the core material corresponds to the volume of the pin which does not project beyond the core material.
  • the core composite structure may, in addition to the core material, preferably cover layers of z.
  • thermoplastic prepregs thermosetting prepregs, glass fiber or carbon fiber reinforced plastics, semi-finished textile products, aramid fibers or polymeric material.
  • thermosetting prepregs glass fiber or carbon fiber reinforced plastics
  • semi-finished textile products aramid fibers or polymeric material.
  • the respective methods of bonding with the core material are known to those skilled in the art.
  • the core composite structure includes cover layers of polymeric material.
  • cover layers are usually connected by means of an adhesive film with the core material.
  • the cover layers contain the same thermoplastic material or the same mixture of thermoplastics as the core material as a matrix.
  • the polymeric constituents of the cover layers consist of the same thermoplastic material or the same mixture of thermoplastics as the polymeric constituent of the core material.
  • the polymeric constituents of the cover layers, the polymeric constituents of the core material, and the polymeric constituent of the posts are made of the same thermoplastic or blend of thermoplastics.
  • the pin is fiber reinforced and consists of these fibers and the same thermoplastic or blend thermoplastic plastics such as the core material. Suitable cover layers are mentioned above.
  • thermoplastic material When using the same thermoplastic material can optionally be dispensed with the adhesive film and the outer layers directly with the core material z. B. be connected by means of heat transfer and diffusion bonding of the polymers.
  • the insertion of the pin can be done very quickly, e.g. by an arrangement of ultrasonically-activated press-fit devices.
  • the pin is preferably not heated directly.
  • An advantage of the invention is that a support on which the entire core assembly rests during the process is not required. It is sufficient if the core assembly rests only at the point at which the pin is introduced and the core composite or the overlay be repositioned in order to introduce a pin at another point of the core composite.
  • the material of this overlay is usually chosen such that the stud can not bond to the overlay (e.g., Teflon or metal).
  • the invention further relates to a reinforced core composite obtainable from the process according to the invention.
  • the invention further relates to an aircraft comprising a reinforced core composite according to the invention.
  • the preferred embodiments of the method are also preferred embodiments of the reinforced core composite, the reinforced core composite obtainable from the method according to the invention and the aircraft comprising a reinforced core composite according to the invention.

Abstract

Verfahren zur Herstellung verstärkter Kernverbunde aufweisend die Schritte: - einbringen eines Stiftes in einen schaum- oder gefüllten bienenwabenförmigen Kernwerkstoff, wobei - der Stift und der Kernwerkstoff einen thermoplastischen Kunststoff oder eine Mischung thermoplastischer Kunststoffe enthalten; und - der Stift derartig erhitzt wird, dass der Kernwerkstoff beim Einbringen des Stiftes an der Einbringstelle erweicht oder schmilzt; und/oder - der Kernwerkstoff an der Einbringstelle erhitzt wird, so dass der Kernwerkstoff erweicht oder schmilzt.

Description

    TECHNISCHES GEBIET
  • Die Erfindung betrifft die Gestaltung sowie die Herstellung von in Dickenrichtung des Kernverbundes durchsetzenden Armierungselementen zur Verstärkung von Kernverbundstrukturen.
  • Die Erfindung eignet sich zur Armierung von Kernverbund-Strukturen. Kernverbundstrukturen enthalten üblicherweise eine relativ dicke Kernschicht geringer Rohdichte, z.B. aus Schaumstoff oder aus vertikal verlaufenden Zellen mit hexagonalem Querschnitt gebildete wabenartige Kernstruktur, und optional Deckschichten.
  • Mit Hilfe dieser Erfindung können die transversalen (z. B. Druck- bzw. Zugsteifigkeit und -festigkeit) senkrecht zur Ebene des Kernverbundes und die Schubsteifigkeit und -festigkeit in der Ebene des Kernverbundes verbessert werden.
  • Zudem wird durch die Verwendung weniger verschiedener Materialien die Recyclingfähighkeit des Materials verbessert.
    • HINTERGRUND
  • Aufgrund des guten Verhältnisses von Steifigkeit und Festigkeit zur Dichte finden im Bereich des Flugzeugbaus Verbundwerkstoffe und insbesondere Kernverbundstrukturen einen breiten Anwendungsbereich. Solche Verbundwerkstoffe, beispielsweise Kernverbundstrukturen, werden im Allgemeinen aus einer oberen und einer unteren Deckschicht oder Decklage gebildet, zwischen denen sich zur Erhöhung der Steifigkeit eine Schicht geringer Rohdichte, z.B. aus Schaumstoff oder aus vertikal verlaufenden Zellen mit hexagonalem Querschnitt gebildete wabenartige, in der Regel gefüllte, Kernstruktur befinden kann.
  • Schaumstoffe sind insbesondere bei der Bauteilherstellung sowie im Bereich der erweiterten Bauteileigenschaften aufgrund ihrer Multifunktionalität für die Anwendung in Kernverbunden für großformatige Strukturbauteile, z.B. im Bereich der Luftfahrt, von Interesse. Zur Verstärkung der schaumbasierten Kernverbunde werden üblicherweise Nähtechniken oder Prepreg-Pinningtechniken eingesetzt, mit denen Fasern oder Fäden in Hartschaumbauteile eingebracht werden können. Nach einem Harzinfiltrationsprozess tragen die mit Fasern durchsetzten Bereiche dann zur mechanischen Verstärkung des Schaumstoffs bei.
  • Bei den zur Verstärkung eingebrachten Fasern oder Fäden kann es sich um sog, Rovings handeln, welche aus parallel verlaufenden Fasern bestehen. Auch kann es sich um Fäden handeln, die aus verdrillten oder verzwirnten Fasern bestehen
  • Bei bekannten Nähverfahren dringt zunächst eine Nadel in den Schaumstoff ein und durchsticht diesen. Gleichzeitig bringt die Nadel den Faden in den Schaumstoff ein. Hierbei erstreckt sich während des Einsteckens in den Schaumstoff der Faden parallel zu und im Wesentlichen über die ganze Länge der Nadel. Die Lochgröße des Einstichloches wird somit durch den Nadeldurchmesser und die Stärke des Fadens bestimmt.
  • Nach dem Rückzug der Nadel aus dem Schaumstoff oder Textil verbleibt ein Loch, dessen Durchmesser im Vergleich zum Durchmesser des eingebrachten Fadens verhältnismäßig groß ist. Dies führt dazu, dass nach der Infiltration mit einem Harz der nicht mit Fasern ausgefüllte Lochbereich mit Harz gefüllt ist, was zu erhöhtem Gewicht des fertigen Bauteils führen kann, welches insbesonders in der Luft- und Raumfahrt vermieden werden soll.
  • DE 10 2005 024 408 A1 beschreibt die Verstärkung von Schaumwerkstoffen mittels eines Knüpfverfahrens, bei dem zunächst die Nadel das zu verstärkende Material (den Schaumwerkstoff) durchsticht und erst dann, im Bereich der Unterseite des Schaumwerkstoffes, das textile Halbzeug aufnimmt und bei der folgenden Rückwärtsbewegung durch das gestochene Loch zieht.
  • Auf diese Weise kann der Lochdurchmesser insgesamt verhältnismäßig klein gehalten werden
  • WO 2007/012353 beschreibt ein Fertigungsverfahren zur Armierung von Kernmaterialien für Kernverbunde wobei zunächst ein Loch mittels eines Greifers in den Kernverbund gestochen wird und das Verstärkungsmaterial durch diesen Greifer in das Kernmaterial gezogen wird. Jedoch kann die Verbindung zwischen Verstärkungsmaterial und Kernmaterial noch verbessert werden.
  • Es ist eine Aufgabe der Erfindung eine verbesserten Kernverbund bereitzustellen.
  • Es sind ein Verfahren zur Herstellung verstärkter Kernverbunde, ein Kernverbund und ein Luftfahrzeug mit einem Kernverbund gemäss den Merkmalen der unabhängigen Ansprüche angegeben. Weiterbildungen der Erfindung ergeben sich aus den Unteransprüchen.
  • Die beschriebenen Ausführungsformen betreffen gleichermaßen das Herstellungsverfahren, das Werkzeug, die Sandwichstruktur und das Luftfahrzeug.
  • Die Erfindung betrifft ein Verfahren zur Herstellung verstärkter Kernverbunde, das Verfahren aufweisend die Schritte:
    • einbringen eines Stiftes in einen schaum- oder gefüllten bienenwabenförmigen Kernwerkstoff
      wobei
    • der Stift und der Kernwerkstoff einen thermoplastischem Kunststoff oder eine Mischung thermoplastischer Kunststoffe enthalten;
      und
    • der Stift derartig erhitzt wird, dass der Kernwerkstoff beim Einbringen des Stiftes an der Einbringstelle erweicht oder schmilzt; und/oder
    • der Kernwerkstoff an der Einbringstelle erhitzt wird, so dass der Kernwerkstoff erweicht oder schmilzt.
  • Die Kernvernbunde erhältlich aus dem erfindungsgemäßen Verfahren weisen eine gute Stabilität auf. Zudem verbindet sich der Stift direkt mit dem Kernmaterial, da sowohl Stift als auch Kernmaterial bei dem Vorgang erweichen und sich verbinden. Es wird angenommen, dass beim Einbringen des Stiftes Material des Kernmaterial verdrängt, welches die angrenzenden Poren teilweise füllt und so zu einer größeren Kontaktfläche zwischen Kernmaterial und Stift führt welches zu der erhöten Stabilität führt.
  • "Erwärmen" und "erhitzen" wird im folgenden synonym verwendet
  • Geeignete thermoplastische Kunststoffen sind beispielsweise Polyetherimid, Polyetheretherketone, Polyamid, Polyimid, Polyethersulfon, Polyurethan oder Polyvinylchlorid oder Mischungen hiervon.
  • Polyamid, Polyetherimid, Polyetheretherketone, oder Mischungen hiervon sind bevorzugt, z.B. eine Mischungen aus Polyetherimid und Polyetheretherketon in einem Gewichtsverhältnis von 65:35 bis 35:65.
  • Der Ausdruck "polymerer Bestandteil" bedeutet die Gesamtheit aller im jeweiligen Material, z.B. Stift, Kernmaterial, enthaltenen Polymere.
  • In einer Ausführungsform enthalten der Stift und der Kernwerkstoff die gleiche Art oder Arten von thermoplastischem Kunststoff(en).
  • Gleiche Art von thermoplastischem Kunststoff bedeutet, dass es sich um denselben Kunststofftyp jedoch das Material des Kerns und des Stiftes unterschiedliche physikalische Eigenschaften, z.B. Molekulargewicht, haben kann. Dies soll an folgendem nicht-einschränkenden, theoretischen Beispiel erläutert werden: Der Stift enthält beispielsweise ein Polyetherimid mit einem Molekulargewicht von 50000 g/mol und das Kernmaterial ein Polyetherimid mit einem Molekulargewicht von 80000 g/mol. Die Kunstoffe sind somit vom selben Typ (Polyetherimid) weisen jedoch unterschiedliche Molekulargewichte auf, sind also die gleiche Art von thermoplastischem Kunststoff.
  • Stift und/oder Kernmaterial können auch Mischungen von thermoplastischen Kunststoffen enthalten.Vorzugsweise werden jeweils die gleichen Arten von thermoplastischen Kunststoffen eingesetzt. Das Mischungsverhältnis innerhalb des Kernmaterials und des Stiftes kann jedoch unterschiedlich sein.
  • Dies soll an folgenden nicht-einschränkenden, therotetischen Beispielen erläutert werden: Der Stift enthält beispielsweise eine Mischung aus einem Polyetherimid mit einem Molekulargewicht von 50000 g/mol und einem Polyetheretherketon mit einem Molekulargewicht von 70000 g/mol in einem Mischungsverhältnis von 50:50. Das Kernmaterial enthält beispielsweise eine Mischung aus einem Polyetherimid mit einem Molekulargewicht von 80000 g/mol und einem Polyetheretherketon mit einem Molekulargewicht von 1200000 g/mol in einem Mischungsverhältnis von 60:40. Die Kunstoffe sind somit vom selben Typ (Polyetherimid/Polyetheretherketon) weisen jedoch unterschiedliche Molekulargewichte und Gewichtsverhältnisse auf, sind also die gleichen Arten von thermoplastischem Kunststoff.
  • Vorzugsweise enthalten der Stift und der Kernwerkstoff den gleichen thermoplastischem Kunststoff oder die gleiche Mischung thermoplastischer Kunststoffe. "Den gleichen thermoplastischem Kunststoff" bedeutet, dass dasselbe Kunststoffmaterial für Stift und Kernmaterial verwendet wird. "Die gleiche Mischung thermoplastischer Kunststoffe" bedeutet, dass die einzelnen Kunstoffe enthaltend in der Mischung gleich sind als auch das Mischungsverhältnis.
  • In einer Ausführungsform enthält der polymere Bestandteil des Stiftes und des Kernwerkstoffes zu je mindestens 90 Gew.-% den gleichen thermoplastischem Kunststoff oder die gleiche Mischung thermoplastischer Kunststoffe.
  • In einer weiteren Ausführungsform besteht der polymere Bestandteil des Kernmaterial zu 100 Gew.-% aus dem gleichen thermoplastischen Kunststoff oder der gleichen Mischung thermoplastischer Kunststoffe wie der Stift.
  • In einer Ausführungsform ist der Stift faserverstärkt. In einer bevorzugten Ausführungsform dieser Ausführungsform ist der faserverstärkte Stift ein Pultrudat.
  • Der Stift besteht vorzugsweise aus dem gleichen thermoplastischen Kunststoff oder der gleichen Mischung thermoplastischer Kunststoffe wie das Kernmaterial und, optional den zur Verstärkung eingesetzten Fasern.
  • Die thermoplastischen Kunststoffe können amorphe oder semikristalline Polymere sein.
  • Die Temperatur mit der der Stift und/oder der Kernwerkstoff an der Einbringstelle erhitzt wird, liegt üblicherweise oberhalb der der Glasübergangstemperatur Tg des thermoplastischen Kunststoffes des Kermaterials bzw. des Stiftes, bestimmt mittels dynamischer Differenzkalorimetrie gemäß DIN 65467.
  • Bei semikristallinen Polymeren ist die Temperatur normalerweise nicht höher als der Schmelzpunkt (Tm) + 50°C des semikristallinen Polymers des Kermaterials bzw. des Stiftes, bestimmt mittels dynamischer Differenzkalorimetrie gemäß DIN 65467.
  • Bei amorphen Polymeren ist die Temperatur normalerweise nicht höher als die Galsübergangstemperature (Tg) + 50°C des amorphen Polymers des Kermaterials bzw. des Stiftes, bestimmt mittels dynamischer Differenzkalorimetrie gemäß DIN 65467.
  • Sollte das Material mehr als eine Glasübergangstemperatur aufweisen, so ist für den o.g. Bereich die niedrigste Glasübergangstemperatur anzusetzen.
  • Sollte das Material mehr als eine Schmelztemperatur aufweisen, so ist für den o.g Bereich die höchste Schmelztemperatur anzusetzen.
  • Wenn Kernmaterial und Stift erhitzt werden wird normalerweise die Temperatur des Kernmaterials und des Stiftes aus oben genannten Bereichen ausgewählt.
  • Die Querschnittsfläche des Stiftes beträgt üblicherweise nicht mehr als 35 mm2
  • Der Stift kann z.B. rund, oval sein oder Ecken aufweisen.
  • In einer Ausführungsform wird nur das Kernmaterial erwärmt. In dieser Ausführungsform wird der Stift indirekt bei Kontakt mit dem erhitzen Kernmaterial ebenfalls erwärmt.
  • In einer anderen Ausführungsform wird der Stift und optional das Kernmaterial erhitzt. In dieser Ausführungsform kann der Stift spitz sein um ein Einbringen in das Kernmaterial zu erleichtern.
  • Um das Kernmaterial lokal zu erwärmen ist das Kermaterial vorteilhafterweise partikelverstärkt. Diese Partikel sind vorzugsweise metallische Partikel. Durch metallische Partikel kann z.B. Induktionserwärmung genutzt werden. Aber auch die Erhitzung mittels LEDs, Laser und Elektronenstrahlen wird dadurch erleichtert.
  • Vor Einbringen des Stiftes kann optional ein Loch in das Kernmaterial gebohrt oder gestanzt werden. Ein derartiges Loch ist üblicherweise kleiner als der Stift, der eingebracht wird. "Kleiner" bedeutet in diesem Fall, dass nicht nur die Querschnittsfläche des Loches kleiner ist als die Querschnittsfläche des Stiftes, sondern, dass die Querschnittsfläche des Loches vollständig innerhalb der Querschnittsfläche des Stiftes liegt.
  • Durch ein derartiges Loch wird die Menge an Kernmaterial, welches der Stift beim Einbringen verdrängt reduziert welches zusätzlich zu einem reduzierten Gewicht der Kernverbundstruktur führt. Dies ist insbesondere in der Luft- und Raumfahrt von Vorteil. Zudem wird bei Stiften mit größeren Querschnitten, z.B. 20 mm2 oder mehr, die Gefahr verringert, dass erweichtes oder geschmolzenes Kernmaterial aus dem Kern herausgerückt wird welches beseitigt werden muss.
  • Die Erwärmung des Stiftes bzw. des Kernmaterials kann beispielsweise durch LEDs, Laser, Elektronenstrahlen oder Induktion erfolgen. Derartige Methoden sind dem Fachmann bekannt.
  • Im Fall der Erwärmung des Kernmaterials an der Einbringstelle beträgt das Volumen des Kernmaterials welches erhitzt wird, vorzugsweise auf die oben genannten Temperaturbereiche, nicht mehr als das vierfache des Volumens welches der Stift innerhalb des Kernmaterials einnimmt, vorzugsweise nicht mehr als das dreifache.
  • Der Stift kann über das Kernmaterial hinausragen oder mit dem Kernmaterial abschließen. Im Falle eines Stiftes, der auf beiden Seiten mit dem Kermaterial abschließt, entspricht das Volumen welches der Stift innerhalb des Kernmaterials einnimmt dem Volumen des Stiftes. Sollte der Stift auf einer oder beiden Seiten hinausragen entspricht das Volumen welches der Stift innerhalb des Kernmaterials einnimmt, dem Volumen des Stiftes welches nicht über das Kernmaterial hinausragt.
  • Die Kernverbund-Struktur kann neben dem Kernmaterial vorzugsweise Deckschichten aus z. B. thermoplastische Prepregs, duroplastische Prepregs, Glasfaser- oder Kohlefaserverstärkten Kunststoffen, textilen Halbzeugen, Aramidfasern oder polymerem Material aufweisen. Die jeweiligen Verfahren zur Verbindung mit dem Kernmaterial sind dem Fachmann bekannt.
  • In einer Ausführungsform enthält die Kernverbundstruktur Deckschichten aus polymerem Material.
  • Diese Deckschichten werden üblicherweise mittels eines Klebefilms mit dem Kernmaterial verbunden.
  • In einer bevorzugten Ausführungsform enthalten die Deckschichten den gleichen thermoplastischem Kunststoff oder die gleiche Mischung thermoplastischer Kunststoffe wie das Kernmaterial als Matrix. In einer weiteren bevorzugten Ausführungsform bestehen der polymere Bestandteile der Deckschichten aus dem gleichen thermoplastischem Kunststoff oder der gleichen Mischung thermoplastischer Kunststoffe wie der polymere Bestandteil des Kernmaterial. In einer besonders bevorzugten Ausführungsform bestehen der polymere Bestandteile der Deckschichten, der polymere Bestandteile des Kernmaterials und der polymere Bestandteil der Stifte aus dem gleichen thermoplastischem Kunststoff oder der gleichen Mischung thermoplastischer Kunststoffe. Wie oben bereits erwähnt ist der Stift in einer bevorzugten Ausführungsform faserverstärkt und besteht aus diesen Fasern und dem gleichen thermoplastischem Kunststoff oder der gleichen Mischung thermoplastischer Kunststoffe wie das Kernmaterial. Geeignete Deckschichten sind oben erwähnt.
  • Bei Verwendung des gleichen thermoplastischen Kunststoffes kann optional auf den Klebefilm verzichtet werden und die Deckschichten direkt mit dem Kernmaterial z. B. mittels Wärmeübertrag und Diffusionsverbindung der Polymere Verbunden werden.
  • Abhängig von der Härte des Stiftes kann der die Einbringung des Stiftes sehr schnell erfolgen, z.B. durch eine Anordnung von ultraschallanimierten Einpressvorrichtungen. Hierbei wird vorzugsweise der Stift nicht direkt erhitzt.
  • Ein Vorteil der Erfindung ist, dass eine Auflage auf welcher der gesamte Kernverbund während des Verfahrens aufliegt nicht erforderlich ist. Es ist ausreichend, wenn der Kernverbund nur an der Stelle aufliegt an der der Stift eingebracht wird und der Kernverbund oder die Auflage neu posititioniert werden um an einer anderen Stelle des Kernverbundes einen Stift einzubringen. Das Material dieser Auflage wird üblicherweise derart gewählt, dass der Stift sich nicht mit der Auflage verbinden kann (z.B. Teflon oder Metall).
  • Die Erfindung betrifft ferner einen verstärkten Kernverbund enthaltend:
    • einen schaum- oder gefüllten bienenwabenförmigen Kernwerkstoff; und
    • Stifte innerhalb des Kernwerkstoffes;
      wobei
    • der Stift und der Kernwerkstoff einen thermoplastischem Kunststoff oder eine Mischung thermoplastischer Kunststoffe enthalten.
  • Die Erfindung betrifft ferner einen verstärkter Kernverbund erhältlich aus dem Verfahren gemäß der Erfindung.
  • Die Erfindung betrifft ferner ein Luftfahrzeug enthaltend einen verstärkten Kernverbund gemäß der Erfindung.
  • Die bevorzugten Ausführungsformen des Verfahrens sind ebenfalls bevorzugte Ausführungsformen des verstärkten Kernverbund, des verstärkten Kernverbunden erhältlich aus dem Verfahren gemäß der Erfindung und des Luftfahrzeuges enthaltend einen verstärkten Kernverbund gemäß der Erfindung.

Claims (13)

  1. Verfahren zur Herstellung verstärkter Kernverbunde, das Verfahren aufweisend die Schritte:
    - einbringen eines Stiftes in einen schaum- oder gefüllten bienenwabenförmigen Kernwerkstoff
    wobei
    der Stift und der Kernwerkstoff einen thermoplastischen Kunststoff oder eine Mischung thermoplastischer Kunststoffe enthalten;
    und
    - der Stift derartig erhitzt wird, dass der Kernwerkstoff beim Einbringen des Stiftes an der Einbringstelle erweicht oder schmilzt; und/oder
    - der Kernwerkstoff an der Einbringstelle erhitzt wird, so dass der Kernwerkstoff erweicht oder schmilzt.
  2. Das Verfahren gemäß Anspruch 1 wobei das Kernmaterial partikelverstärkt ist.
  3. Das Verfahren gemäß Anspruch 2, wobei das Erhitzen durch Induktion erfolgt.
  4. Das Verfahren gemäß einem der vorangegangenen Ansprüche wobei der Stift faserverstärkt ist.
  5. Das Verfahren gemäß einem der vorangegangenen Ansprüche wobei der Stift ein Pultrudat ist.
  6. Das Verfahren gemäß einem der vorangegangenen Ansprüche wobei der Kernwerkstoff und, optional, der Stift erhitzt wird.
  7. Das Verfahren gemäß Anspruch 6 wobei ausschließlich der Kernwerkstoff erhitzt wird.
  8. Das Verfahren gemäß einem der vorangegangenen Ansprüche wobei der Stift und, optional, der Kernwerkstoff erhitzt wird.
  9. Das Verfahren gemäß Anspruch 8 wobei ausschließlich der Stift erhitzt wird.
  10. Das Verfahren gemäß einem der vorangegangenen Ansprüche wobei der thermoplastische Kunststoff oder die Mischung thermoplastischer Kunststoffe aus Polyetherimid, Polyetheretherketone, Polyamid, Polyimid, Polyethersulfon, Polyurethan oder Polyvinylchlorid oder Mischungen hiervon ausgewählt ist.
  11. Das Verfahren gemäß Anspruch 10, wobei der thermoplastische Kunststoff oder die Mischung thermoplastischer Kunststoffe aus Polyamid, Polyetherimid, Polyetheretherketone, oder Mischungen hiervon ausgewählt ist.
  12. Verstärkter Kernverbund erhältlich aus dem Verfahren gemäß einem der vorangegangenen Ansprüche.
  13. Luftfahrzeug enthaltend einen verstärkten Kernverbund erhalten aus dem Verfahren gemäß einem der vorangegangenen Ansprüche 1 bis 11 oder enthaltend einen verstärkten Kernverbund gemäß Anspruch 12.
EP14196374.4A 2013-12-05 2014-12-04 Verfahren zur herstellung von verstärkten materialien und material erhältlich aus diesem verfahren Active EP2886302B1 (de)

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